Introduction: Phi Box

I made this to be cut on the UNIVERSAL 60 Watt CO2 Lasers in the Chandler, Az TECHSHOP.

This is a laser cut pattern that assembles into a box with a wooden hinge. Its about (approximately, almost, nearly) the size of a cigar box with proportions that are supposed to fit the PHI proportion

Step 1: Cut the Pieces Out Using the Laser Cutter

Step 2: Lay Out the Pieces for the Lower Part of the Box

Set the pieces up like this and get ready to glue the bottom together.

Note: There is a front and a back and a left and right side. Look at the picture.

Arrange the pieces like the picture before you glue the lower part of the box together.

The circled corners on the side panels should be next to the panel with the additional cutouts for the hinge pivot tabs..

I put CA gel glue at a couple tabs to hold the pieces together quickly during assembly. for the rest of the tabs I use a watered down (50/50) wood glue solution.

Note: regular strength wood glue works fine but excess may ooze out and turn yellow when it dries. Careful application may minimize 'ooze'.

SPECIAL NOTE: DO NOT GLUE the hinge pivot tab

Step 3: Put the Bottom of the Box Together

Assemble the box using hand pressure to temporarily hold the pieces together. The CA gel glue bonds almost instantly. The wood glue takes a bit longer.

Note: I've used clamps before. My experience has been that the force applied by clamps can warp the panels.If you are working with exceptionally warped panels, it might be necessary to use clamps.

Step 4: Assemble the Pieces for the Lid of the Box

Note: The following steps my require some practice. For the first assembly, I would recommend accomplishing the following steps without glue.

Assembly order will be up to you.

I start with the outer side panels. The hole in the side panel fits over the hinge pivot tab in the bottom back panel.

Then I install the four center hinge braces. The holes in the braces fit over the hinge pivot tabs in the back panel. The front of each brace rests on the bottom front panel until the lid front panel is installed.

Then I install the lid back panel. The two tabs that extend down go between the hinge braces at the hinge point. The outer edges should fit into the outer hinge panels.

Then install the front panel.

Note: This will require some patience/practice. The tabs fit into holes, but there are several pieces to move around during the assembly process.

After you have assembled and disassembled the lid a couple times, you should be ready to glue the parts together.

Step 5: Install the Top of the Lid

I add CA gel glue to a couple points to hold the piece together while the wood glue sets up

Lay the lid in place and patiently push the pieces together. All the tabs fit into the slots of the opposing parts. It is not necessary to pound the parts together. When they line up, they slip into place.

If you have accomplished the dry-fit, you will understand how tricky the assembly can be, but the pieces will go together.

Once together, hold the pieces together with hand pressure.

It takes 20 to 30 seconds for the CA gel glue to set up, then another 5 to 10 minutes for the wood glue to set up enough to allow handling.

The design is meant to be taken from/modified/improved upon. I was thinking someone could use the hinge design for their own projects. BTW, the hinge is made to be cut from a 1/4 in ply with a finished dimension of 0.210 ( I get mine from Lowes). If you use a 1/4 Baltic Birch, the finished dimension might be thicker and the drawing may need to be scaled up.

I was searching for a while for a solution like yours, simple but very functional

I modified your project having in mind to use 5 mm (about 0.20 inches) wood and The hinge parts will have a millimeter (0,03 inches) of difference between the two sides so should not touch each other and opening should be quite easy